16th September 2014 - No longer baffled except for one thing!

The baffle material was riveted into place and the the edges rounded. In the four places where the sections of baffles meet the overlap in the material was screwed together rather than riveted to allow the sections to be removed. The inter-cylinder baffles were fitted and tie rods threaded to pull the under sections of the cylinder baffles together. Vans supply stainless steel rod for the tie rods and assume you will have a 6-32 die cutter to hand. Holes were cut in the rear baffles to mount the plates through which the plug wires will pass
The idea of the baffles is that the air flowing in through the ducts in the cowl is forced between and round the cylinders ensuring even cooling. The flaps in front of the no. 1 and no. 2 cylinders try to balance the cooling front to back.
Once all this was finished the top cowl was fit into place when my mistake was revealed. My perfectly placed Oil filler flap was on the wrong side of the rear baffle. It provided access to the rear cylinder and nothing else!
Luckily mistakes in fibreglass are reasonably easy to correct. The section of the cowl around the door was cut out as a rectangle together with a  similar sized section behind it. The rectangular piece was then cut in half so that I had a piece with the door and its surround and a second blank piece.
With the cowl fastened to the bench with some plastic sheet below it, the two pieces were then glassed back into the cowl in the reverse direction. A bit of filler made good the joints. Then a coat of primer was applied to the whole top cowl to reveal the inevitable pinholes in the fibreglass. A mixture of micro-balloons and resin is used to fill the pinholes. The picture shows it prior to final sanding. This is a mind-numbing job so I'll be doing it a bit at a time as motivation occurs.